Fuel and air induction system

Abstract: An integrated fuel and air induction system for use on an internal combustion engine includes a two-piece intake manifold (12) with a fuel metering body (36) forming an integral portion thereof. The manifold (12) contains the fuel metering body (36) which forms a fuel plenum (64) therein. The plenum (64) has an inlet (74) for pressurised fuel, a pressure regulator (84) and a fuel outlet (76). Disposed within the fuel plenum (64), in fluid communication with one another, the inlet (74) and the outlet (76), are a plurality of fuel injectors (102). The fuel injectors (102) have outlets (118) which extend through the fuel meter body (36) and deliver fuel to the intake ports of the associated engine through flexible fuel lines (128) terminated by pressure pulse activated poppet nozzles (136) providing a significant degree of application flexibility. The fuel meter body (36) mounts within the intake manifold (12) such that fuel and electrical connections extend out of the manifold (12) for simplified source attachment.

Description: This invention relates to an integrated fuel and air induction system for an internal combustion engine. In the fuel injection systems disclosed in US-A-5,070,845 and US-A-5,082,184, a single injector meters fuel which is distributed to a plurality of fuel lines having nozzle terminations. The nozzles discharge fuel adjacent the engine intake ports. Such a system has, as a principle feature or benefit, the localisation of fuel metering components in a single fuel metering body which can be located inside of the intake manifold. The use of a single injector dictates that each nozzle and, as a result, each cylinder be fuelled simultaneously, without regard to cylinder timing. The result is less than optimal engine and emission performance. In addition, the location of the fuel meter body within the intake manifold proliferates the connective hardware required for fuel and electricity to pass through the wall of the manifold. In the fuel injection systems disclosed in US-A-4,510,909 and US-A-4,586,477, fuel rails deliver fuel to a plurality of outwardly extending electromagnetic fuel injectors. The rail-injector assembly is secured to the exterior of the intake manifold of an engine with the injectors received in openings therein for delivery of fuel to associated engine cylinders. The use of individual injectors for each cylinder permits optimisation of the fuelling event. The location of the fuel rail and its relatively large surface area may cause fuel passing through the rail to be subjected to significant heating, increasing the likelihood of hot fuel handling problems and running loss emissions. Fuel rails are application specific, and a separate rail must be designed for each engine. In addition, the electromagnetic injectors used in such systems have relatively large diameters resulting from the placement of the solenoid in the point-of-delivery device. As such, significant limitations are placed on injector location and fuel targeting. The present invention seeks to provide an improved fuel and air induction system. According to the present invention, there is provided an integrated fuel and air system for an internal combustion engine as specified in claim 1. The preferred embodiment includes a fuel and air induction system having a fuel meter body which functions as a system chassis for the mounting of primary fuel system components. The fuel meter body preferably houses a plurality of individual electromagnetic fuel injectors in a common fuel plenum such that pressure variabilities between the injectors are minimised. The fuel meter body may be configured for assembly within a multi-piece engine intake manifold. The manifold is preferably constructed with an opening for cooperative, sealing engagement with a portion of the fuel meter body such that fuel and electrical connections to the fuel system remain external to the intake air plenum. In a preferred embodiment, the fuel meter body is configured such that both ends of each of the electromagnetic fuel injectors extend out of the fuel plenum to facilitate the attachment of fuel delivery tubes to the injector outlets and electrical connectors to the solenoid ends. Each injector is associated with a flexible fuel line and a poppet nozzle which facilitates delivery of fuel to intake locations corresponding to each engine cylinder. Location of the metering portion of the fuel system, remote from the fuel nozzle, supports a smaller terminal unit therefore enhancing the positioning of the nozzle and targeting of fuel while allowing individual engine cylinder fuelling. It is possible to provide a compact fuel metering body which delivers fuel sequentially to a plurality of engine cylinders through flexible tubes supplied by individual electromagnetic fuel injectors and terminated by pressure activated poppet nozzles. There may be provided a centralised and flexible location of a fuel system with sequential fuel delivery across a wide range of engine configurations without the necessity for redesign of key fuel system components. It is possible to provide sequential fuel delivery with reduced mass, surface area and fuel volume, thereby significantly lowering the transfer of heat, generated in the engine compartment, to the fuel system. The fuel metering body is preferably integrally located within the relatively cool environment of the intake manifold, rather than on the exterior of the manifold, providing additional benefits relative to fuel system heating. It is also possible to simplify significantly supply of fuel and electric to the fuel system by integrating the fuel meter body with the intake manifold wall, thereby to eliminate the necessity of moving fuel and electric through a manifold wall interface to an internally mounted fuel meter body. An embodiment of the present invention is described below, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is an exploded perspective view of an embodiment of integrated fuel and air induction system for an internal combustion engine; Figure 2 is a partial cross-sectional view of the integrated fuel and air induction system of Figure 1 in assembled form; Figure 3 is a partial cross-sectional view of the fuel distributor of Figure 1 taken along line 3-3 of Figure 1; Figure 4 is a cross-sectional view of the fuel distributor of Figure 3 taken along line 4-4 of Figure 3; and Figure 5 is a side view partially in cross-section of the fuel distributor of Figure 3 taken along line 5-5 of Figure 3. Figure 1 shows an integrated fuel and air induction system 10 for supply of metered air and fuel to the intake ports of an internal combustion engine (not shown). The integrated fuel and air induction system includes a two piece intake manifold 12 having upper and lower manifold members 14 and 16, respectively. The lower intake manifold member 16 is configured for assembly to the piston deck of an internal combustion engine block, the manifold shown in Figure 1 being of the type for a v-configured engine. Air passages such as intake runners 18 in lower member 16 transfer intake air from the intake manifold 12 to the intake ports of the engine while fuel nozzle openings 20 accommodate fuel nozzles, to be described in further detail below, for delivering metered pulses of fuel into the intake runners 18. The upper intake manifold member 14 is configured for sealing engagement with the lower member 16 along mating surfaces 22 and 24 to form an intake air plenum 26 therebetween (see Figure 2). A first opening 28 in the upper member 14 is configured to receive intake air through a throttle body assembly 30 while a second opening 32 receives a portion of a fuel meter body 34 of a fuel injection system 36, disposed within the assembled air intake manifold 12. Referring now to Figure 2, fuel meter body 34 is assembled into the intake manifold 12 as an integral component. Attachment means such as support bracket 38 is assembled to the lower member 16 using screws 40 or other suitable means for attachment. Slots 42 in the support bracket 38 are engaged by corresponding attachment pegs 44, depending from the exterior of the fuel meter body 34, to support the fuel meter body in a fixed position within the manifold 12. A flanged sealing platform 46 depends from an upper portion of the fuel meter body 34. A resilient sealing member such as O-ring 48 disposed about the platform engages a corresponding surface 50, extending around opening 32 in upper member 14, with a leak-free seal to close the opening and secure the fuel meter body 34 integrally with the upper intake manifold member 14. Referring now to Figures 3, 4 and 5, the fuel meter body 34 of the integrated air and fuel induction system 10 functions as a chassis for the fuel system, to which substantially all fuel system components are mounted. The fuel meter body may be constructed of any suitable material for such an environment, such as glass filled nylon. The fuel meter body has a top 52, sides 54,56,58,60, and a bottom 62 which together form an internal fuel plenum 64 within the body. Associated with a side of the plenum 64 are a pressurised fuel inlet 66 and a fuel outlet 68. Both the inlet and the outlet 66,68 have terminal ends which extend through the flanged sealing platform 46 such that fuel system supply and return connections, necessary to supply fuel to the plenum 64 can be made externally of the intake manifold 12. The terminal ends of inlet and outlet 66,68 have walls 70,72 extending into fuel meter body 34 for accepting terminal end portions of supply and return connections 74,76. Resilient sealing members such as O-rings 78 are disposed between the connections 74,76 and walls 70,72 to prevent leakage of fuel. The connections are secured in place using a clamping member 80 mounted on studs 82. An opening in side 60 of fuel plenum 64 accommodates fuel pressure regulator 84. An annular wall 86 defines a seat for pressure regulator 84. A sprung retainer 88 engages pegs 90, which depend from the wall 86, and an annular collar 92 on regulator 84 to fix the regulator in position. The regulator 84 operates in a conventional manner known in the art, allowing fuel pressure in fuel plenum 64 to rise to a desired level, at which time fuel is permitted to pass through the regulator 84 and into a tubular passage 94 extending from the regulator, through fuel plenum 64 to terminate at the base of fuel outlet passage 68. A resilient sealing member such as O-ring 96 prevents fuel from passing between the tubular passage 94 and the fuel plenum 64. The location of the fuel pressure regulator 84 relative to the fuel inlet 66 establishes end-to-end fuel flow through the fuel plenum 64. The bottom 62 of plenum 64 includes a plurality of cylindrical openings 98 which extend into the plenum and have walls which form cylindrical chambers 100 extending from the bottom to the top 52 of the plenum. Each chamber 100 opens (Figures 3 and 4) to the plenum 64, thereby to place each of the cylindrical chambers in fluid communication with the others. Each cylindrical chamber 100 slidingly receives an electromagnetic fuel injector 102 therein. The injectors 102 extend from the top to the bottom of the chambers 100 with electrical connectors 104 at the first or upper ends thereof, extending through corresponding openings 106 in the top 52 of the fuel plenum 64. The openings 106, through which the electrical connectors 104 pass, open into a pocket 108 formed by wall 110 which extends from flanged sealing platform 46. The walled pocket 108 permits the attachment of an electrical connector 112, externally of the intake manifold 12. Attachment studs 114 extending from the exterior of the wall 110 engage corresponding tabs 116 extending from the connector 112 to secure the connector against displacement. The connector 112 operates to seal the electrical connections 104 against moisture and other contamination. The second, outlet end 118 of each fuel injector 102 projects outwardly from the cylindrical openings 98 in the bottom 62 of the fuel plenum 64, Figure 5. To secure against extrusion of the injectors 102 from the fuel meter body 34 under the pressure of fuel in the plenum 64, a retaining plate 120 attaches to the bottom of the fuel meter body and is secured by bolts 122 attached to studs 124. The retaining plate 120 has openings 126, providing clearance for the outlet ends 118 of the injectors 102 and facilitating the attachment of fuel delivery lines 128 thereto. The fuel delivery lines 128, in the preferred embodiment, are fabricated from a suitable, fuel resistant flexible material such as nylon. Lines 128 are attached at a first end 130 to the outlet end 118 of the injectors 102. An annular ridge 132 on the outer surface of the injector outlet end 118 is operable to prevent disengagement of the fuel line therefrom. The second end 134 of each fuel line 128 is terminated by a pressure pulse activated poppet nozzle 136. The nozzle 136 is carried in a mounting sleeve 138 having integral attaching means such as clips 140. The sleeve and nozzle are removably insertable into the fuel nozzle openings 20 in the lower member 16 of intake manifold 12 for delivery of fuel to the intake runners 18. The flexible fuel lines 128 that deliver fuel from the fuel meter body 34 to the poppet nozzles 136 maximise the applicability of the fuel system to various engine platforms with a minimisation of redesign and part proliferation. As an example, the disclosed system can operate in a 90 degree V-6 engine or a 60 degree V-6 engine with no change to the system. The flexibility of the fuel meter body installation and locatability of the flexible fuel delivery lines render the disclosed fuel system less sensitive to differences in cylinder spacing. In addition, fuel targeting is improved by removal of the fuel metering task, which involves a relatively large solenoid and valve assembly, from the point of fuel delivery in the air plenum, to a centralised fuel plenum. The small size of the poppet nozzle 136 allows enhanced targeting of fuel at the engine intake to be optimised. Resilient sealing members such as O-rings 142,144 are disposed at the first and second ends of the injectors 102, between the injector and the walls of cylindrical chambers 100, to establish a leak-free seal between the fuel plenum 64 and the openings in the top 52 and bottom 62. The fuel injectors 102 have fuel inlets 146 located intermediate of the ends thereof for fluid communication with the fuel plenum 64 of the fuel meter body 34. Fuel enters each injector through its respective inlet 146 and is metered through outlet 118 by valve means (not shown) which are actuated in response to an electrical signal from a controller which monitors engine operating conditions. Pulses of pressurised fuel are transmitted through fuel lines 128 to activate the poppet nozzles 136 such that a metered quantity of fuel is injected into the intake air flow at an optimised time and rate. The distance from the pressure regulator 84 to the injectors 102 is important in that when an injector opens for an injection event, the fuel pressure in the fuel vessel, in this case the plenum 64, will decrease until the pressure wave induced by the event can move through the fluid to the regulator. Once the wave of reduced pressure reaches the regulator 84 it can respond to the drop in pressure by reducing the fuel bypassed to the fuel outlet 68. The concentration of the fuel injectors 102 in a small volume fuel plenum 64 in which the inlets 146 of each injector are in fluid communication with each other, the pressurised fuel inlet 66 and the fuel outlet 68, maximises the fuelling consistency from injector to injector across the operating range. The close proximity of the fuel injectors 102 to the fuel pressure regulator 84 provides for rapid and uniform regulator to injector interaction. Thus, the described embodiment provides a fuel system for an internal combustion engine having a compact fuel metering body which, when mounted within the intake plenum of the intake manifold, operates as an integral part of the manifold, thereby facilitating the supply of fuel and electrical signals to the injectors disposed therein. The fuel injector body includes a fuel plenum in which a plurality of fuel injectors are disposed in fluid communication with one another, the inlet and the outlet. Such a configuration reduces fuel pressure variability from injector to injector to maximise fuelling consistency. Additionally, the compact fuel metering body minimises the residual heat transferred to the fuel system due to its small volume, reduced surface area and location within the relatively cool environment of the intake manifold. Maximum compatibility with a wide range of engine configurations is provided through the use of fuel lines extending from the injector outlets to the intake runners which, when constructed of a flexible material, are insensitive to the specific point of fuel delivery.

Claims: An integrated fuel and air system for an internal combustion engine comprising an intake manifold (12) including upper and lower members (14,16), the lower manifold member (16) including air passages (18) for the transfer of air from the manifold to an engine, the upper member (14) comprising an air plenum (26) including a first opening (28) configured to receive intake air and a second opening (32) configured to receive a portion of the fuel meter body (34), the upper and lower members being sealingly engageable to one another along mating surfaces to enclose the air plenum; fuel meter body including a top, sides and a bottom forming a fuel plenum (64) therebetween, mounting means (42,44) for fixing the fuel meter body within the air plenum, and a flanged sealing platform (46) extending from the fuel meter body and configured for mating engagement with said second opening (32) in the upper member when the upper member is engaged with the lower member of the intake manifold, the fuel plenum including a pressurised fuel inlet (74) and a fuel outlet (76) opening through the flanged sealing platform and out of the second opening in the air plenum (32), and fuel regulating means (84) associated with the fuel plenum to regulate fuel pressure therein, a plurality of cylindrical openings (100) forming cylindrical chambers which extend through the fuel meter body and open into the fuel plenum such that each chamber is in fluid communication with the other cylindrical chambers in the fuel plenum and is configured to receive a fuel injector (102) therein for support within the fuel plenum such that the injectors are each in fluid communication with one another; each injector comprising an injector body including electrical connection means (104) extending out of openings in the fuel plenum in the region of the sealing platform for attachment to energising means external of the manifold, an outlet (118) extending outward of its respective opening, a fuel inlet (146) coupled to the fuel plenum and valve means operable upon energisation of the injector to meter fuel through the outlet, and a fuel line (128) including a first end connected to the fuel injector outlet and a second end coupled to a pressure pulse activated nozzle. An integrated fuel and air system according to claim 1, wherein the lower manifold member (16) includes a plurality of fuel nozzle openings (20) in communication with the air passages.

Inventors: BRISBANE ROGER MICHAEL, CARBONE DONALD THOMAS, GEIGER SCOTT ALAN, SCHAENZER THOMAS RICHARD, BRISBANE, ROGER MICHAEL, CARBONE, DONALD THOMAS, GEIGER, SCOTT ALAN, SCHAENZER, THOMAS RICHARD
Applicants: GEN MOTORS CORP, GENERAL MOTORS CORPORATION
Application year: 1994
Main classification: F02M35
IPC codes: F02M69, F02M35